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Advances in consumer electronics technology have driven corresponding innovations in components such as films and phosphorescent plastics. A specific example is the thin-wall designs of cellular telephones which created a demand for coatings and resins that will shield the portable electronics from electromagnetic damages. Thus, plastics manufacturers have responded by designing materials that will make it easier for electronic manufacturers to mold thin parts., Electronics manufacturers use advanced resins and coatings to mold thin-wall components that shield electronics from electromagnetic interference. Take a close look at your cell phone, pager, or lap-top computer and [...]

The Indy Racing League (IRL) is addressing persisting issues of race car reliability and safety after a first full season in operation in 1997 that was plagued with too many accidents and engine and mechanical failures. The IRL safety team initially focused its efforts to develop lighter, more crash-friendly gearboxes, a larger impact attenuator and crash-friendly chassis and engines. The IRL is confident that these and other continuing improvements will make for more competitive but safer races.

Polymers may be utilized in designing and constructing the interior and exterior of automobiles. Using polymers for windows, truck beds and body works may minimize the costs in painting, complex forming and assembly of automobiles. Furthermore, advanced automotive designs without expensive metal working processes and design flexibilities on fuel tanks and chassis designs can be achieved by using such innovative plastic.

Medical device manufacturers will benefit significantly from the powder-injection molding (PIM) technique. The approach offers enhanced thermoplastics processing and maximizes the performance features of ceramics, metals and small and complex components. Since it was developed during the 1920s, PIM has evolved to include modern feedstocks and processing devices that offer excellent molding, debinding and sintering control., Powder-injection molding combines the processing ease of thermoplastics with the performance qualities of metals and ceramics, for small, complex components. Some may remember the original style of orthodontic braces made [...]

Engineers are utilizing the benefits of using aliphatic polyketone (PK) resins, which have high moisture absorption qualities in addition to offering a unique balance of mechanical, acoustical and injection-molding qualities, for plastic gears. PK resins, also called Carilon, offer higher creep resistance and outperform nylon and acetal when run against metal which is where the high friction contributes to wear., Engineers use plastic gears for a wide variety of applications in automobiles, computers, electronics, and medical equipment. They provide a lightweight, low-cost means of transmitting power. With less mass and [...]

New advanced gear are available for ice hockey players, snowboard skaters, hikers and fishing aficionados. For ice hockey players, new materials include carbon-graphite sticks by Prokennex, in-line skates by V-Formation Inc, and Nylon wheel supports by DuPont. A new snowboard by Ultimate Sports Inc gives higher impact strength and shock-absorbing capacity. Tent windows made of THV fluorothermoplastic give a better outside view despite freezing temperatures. New polyolefin fins with lower specific gravity make floating easier for fishing enthusiasts., Shopping for sporting goods isn't the simple exercise it was in years past. Today s consumers, as well as store employees, practically need a technical degree to understand equipment. The [...]

The two-year old Indy Racing League (IRL) has set up new guidelines for its racing competitions. The new IRL rules consist of limitations on chassis and engine specifications for the purpose of cutting costs, improving safety and increasing parity. These new chassis and engines was first featured during the Jan 1997 Indy 200 at Walt Disney World and will be seen for the rest of the IRL races. These rules are effective at least until 1999. The 1997 IRL chassis and engine specifications are presented., In its second year of racing, the IRL further distances itself from CART with new chassis and engine specs aimed at cutting costs, improving safety, and increasing parity among teams. [...]

Medical equipment manufacturers are utilizing plastics to produce affordable medical devices as a response to government mandates to reduce the cost of medical services. These new medical devices incorporate the use of advanced resins and the latest in manufacturing processes. Among the new products are a disposable tourniquet, a portable intravenous drug infuser and a heart catheterization manifold. Medical plastics, although still starting to break ground in the healthcare industry, represent a $4.5 billion market worldwide., Plastics are helping health care move out of hospitals and into clinics and homes, thanks to less-invasive surgeries and user-friendly, portable devices. Government mandates aimed at cutting the cost of [...]

Design engineers can use a series of equations on shear and normal stresses to determine the strength requirement of spiral seam weld on a pressure vessel, such as an airplane. These equations were derived by applying stress-transformation equations into a structural element model. Designers can enhance the visualization of stresses through the use of a graphical method., Structural components, such as pressure vessels, crankshafts, rotors, and beams, develop plane or biaxial stresses under normal loading in one or more directions. The problem this creates for designers is [...]

Thermoplastic polyurethanes (TPU) are extensively used in medical emergency situations due to its advantages. Medical equipment and instruments containing TPUs are durable even in freezing conditions. This may be attributed to the absence of additives in TPUs. In designing equipment containing TPUs, designers should examine various considerations such as durometer, low-temperature flexibility, tensile strength, elongation, abration and chemical resistance., Thermoplastic polyurethanes give the durability and performance needed for 'can't fail' applications. When rescue workers rush to save victims of an accident, every second is critical. With all of their [...]

Water ski manufacturers employ a wide range of advanced materials and design technologies to enhance the performance of their products. Most slalom water skis are made of composite materials such as polyurethane, Kevlar, epoxy resin and fiberglass. They are designed using CAM/CAD systems and manufactured using computer-numerical-control machining. The underside of most slalom water skis have fins and flutes to enhance control and reduce drag., Water-ski manufacturers use advanced materials, adjustable features, and computer tools to boost performance. As a sophomore at the University of Washington in 1964, water-skier Herb O'Brien experimented by carving tunnel [...]

Two companies are pioneering in the use of biomedical materials to replace or repair broken bones. Norian Corp. has developed a biocompatible, structural bone replacement material called the Skeletal Repair System, while OsteoMedica Corp. has come up with a porous bioceramic bone substitute. Bone-repair materials are not only stronger than mechanical fixes, but they also help cut down doctor visits, reduce medical costs and speed up the recovery of patients., A nasty fall on the ski slopes lands you A in the emergency room at the local l hospital, and what started out as a spring-break vacation to the Rockies, [...]

Materials engineers are increasingly using non-destructive testing methods to analyze the structural properties of various engineering materials, such as plastics and composites. These methods, which include thermal-wave imaging and ultrasonic inspection technologies, allow detailed examinations of internal structures to measure molecular-scale damage without destroying the samples., Advanced material-testing methods give engineers more ways to examine internal structures without destroying samples. Many engineers and inspectors who evaluate materials probably wish they still had their old comic books [...]

The development of the Steckel Mill Advanced Rolling Technology (SMART) promises to revolutionize the process of producing steel products. Unlike other approaches, the SMART system focuses on producing high-performance steel through enhanced process controls, particularly during rolling. Steel manufactured using SMART are characterized by superior dimensional tolerances, surface quality and processibility. SMART allows production of steel coils with thickness ranging from 0.080 in. to 0.625 in. Discrete plates with a thickness of up to 3 in. can be produced., Advanced rolling methods add more precision, accuracy, and processibility to steel. Though steel making is a basic industry, its modern version depends on an unusual combination of high technology and [...]

A growing number of manufacturing firms are increasingly using rubber tools to make limited-production prototypes and minimize production time. This trend can be attributed to the development of new equipment and materials that supports rapid rubber tooling and prototyping, such as the thin-wall reaction-injection-molding machine and RP 6460 rapid-cure polyurethane., Plastic designs get to market faster thanks to advances in rubber-tooling: equipment and materials. DAVID S. HOTTER Staff Editor Everyone is shooting for shorter development cycles. When they're executed properly, [...]

Fineblanking sheet metal enable machine parts to be mass-produced in one press stroke. Parts produced through this process have tighter tolerances and better finishes than parts produced through other methods such as stamping and die casting. This process combines stamping and extrusion on a triple-action press to naturally harden parts and minimize grinding, milling and drilling. The combination of fineblanking and computer numerical control allows engineers to optimize plant capacity, maximize productivity and reduce the labor requirements of machine part production.

The ISO 14000 standards is aimed at encouraging companies to develop environmental management systems that will filter responsibility among their employees. This goal has encouraged several firms, such as Du Pont, Motorola Inc. and Eastman Kodak Co., to create action plans that will clearly identify corporate roles and responsibilities and enable them to obtain ISO certification., Using lessons learned from complying with ISO 9000, manufacturers plan to take a proactive approach to the new environmental standard. The Exxon Valdez spill was one of the greatest environmental [...]

BMW has launched its 1998 323is automobile. It sports a 2.5-liter 6-cylinder engine and weighs approximately 3,000 pounds. Its engine possesses 168 horsepower and 181 pound-foot of torque. The engine provides increased at lower revolutions as compared to the BMW 318is models. The automobile's five-speed manual transmission enables quick and smooth shifts to different gears. Interior design features include leather seats, digital climate controls, microfiltered ventilation and a 10-speaker stereo. It is priced at $31,685., BMW has long touted itself as provider of the ultimate driving machine, and after driving one for just a week, I have to agree. This was my first experience behind [...]

The 1998 Ford Mustang GT with 4.6-liter V8 engine has several advantages over the 5.0-liter version. Among these are reduced engine vibration via a deep-skirt structural cylinder block rigidly attached to the transmission, fuel economy at about 25 mpg and a new environment-friendly fuel system. Other features include lighter-socket power outlet, additional cup holder and relocation of the clock to the stereo display., If you're a muscle-car fan like me, you know there aren't too many affordably priced sports cars on the market today with high-output engines. The Mustang has become a perennial [...]

The 1998 edition of the Chevrolet Corvette hides its engineering design behind comfortable seats, elegant fittings and convenient electronics that can memorize mirror, climate and audio equipment settings for up to three drivers. Its technical features include an aluminum engine, a full-length perimeter frame welded to bumper beams, suspension adjustment from the driver's seat, hydroformed side rails and a torque that allowed roomier interiors through the relocation of the transmission to the vehicle's rear wheels. Corvette is offered at a suggested retail price of $38,060.

Structural Research and Analysis Corp's Cosmos/Works software is being used by Red Deer, Alberta-based Gris Gun Manufacturing for collet development. Collets are employed to deliver the head of oilfield perforating guns to detonation sites. Gris Gun has posted significant time savings in compressive and tensile load analysis using the program. Cosmos/Works also helps in the the selection of prototype designs., Gris Gun Manufacturing, Red Deer, Alberta, uses Cosmos/Works software from Structural Research & Analysis Corp., Los Angeles, to reduce development time for collets used on oilfield perforating guns. The software [...]

An evaluation of the 1997 Porsche Boxster is presented. The Boxster reflects Porsche's reputation of combining high class and high performance in a car. Its design and machinery boasts several innovations, such as an advanced engine and cooling system that could push the car to a speed of close to 150 mph. The car has some of the advanced devices that driving or riding on it would be an unforgettable experience., The Porsche for the rest of us Hey! What kind of car is that?' That was an often-heard hail during my time with the Porsche Boxster. This powerful two-seater combines [...]

The 1998 Chevy Blazer LS sport utility vehicle has qualities similar to that of a sports coupe. The interior has plenty of space for storing baggage for vacation trips. The vehicle has a smooth ride and top-quality handling due to its Carbon monotube high-pressure gas shocks. It also has the Insta-Trac electronic shifting function allowing riders to shift from two-wheel to four-wheel-drive at any speed. Furthermore, it is priced enough for consumers seeking a more compact version of of sports utility vehicles., In a time when the streets are full of massive sport-utility vehicles (SUVs) with room for. eight passengers, the 1998 two-door Chevy Blazer caters to the more pragmatic and sporty [...]

The 1998 Lexus LX 470 sport utility vehicle supports a 32-valve, 4.7-liter V8 engine that is capable of producing 230 hp and 320 lb-ft of torque. The sport utility vehicle supports torsion bars on an independent front suspension system. It also features side rearview mirrors, electrochromic self-dimming, tilt steering, climate controls and ergonomic seats. The Lexuc LX 470 is priced over $57,000., I didn't know what to expect when I found out I would be test driving a sport-utility vehicle made by Lexus. What could a luxury automobile manufacturer possibly know about [...]

Glass-reinforced polyurethane from Pittsburgh, PA-based Bayer Corp is being used by General Motors in making the instrument panel (IP) for EV1, the world's first production electric vehicle. The IP is composed of a durable and nonreflective polyurethane 1-mm skin that is lightweight yet stiff, and requires low-tooling. It is supported by foam that was fashioned from Baydur 250 IMR structural reaction-injection-molded polyurethane. The 1-mm skin is also being used on the center console, airbag door, and armrest of the EV1., Engineers at General Motors are employing polyurethane resin on the instrument panel (IP) for the EV1, the world's first production electric vehicle. The panel, molded from glass-reinforced polyurethane from Bayer [...]

Boothroyd Dewhurst Inc., Wakefield, RI, and TNO Institute of Industrial Technology, Delft, Netherlands created a Windows-based program, Design for Environment (DFE) V1.0, that analyzes economic and environmental influences on the disassembly of products once they are no longer useful. DFE suggests ways such as material recycling, part reuse and disposal through landfills or incineration.

Toyota's RAV4 sport-utility vehicle has a new, more durable cover for its spare tire. The cover, made from a coextruded sheet of Centrex 833 ASA/AES resin and Lustran 752 ABS resin from Pittsburgh, PA-based Bayer Corp., resist the elements, including ultraviolet rays, and impact from rocks and other off-road debris. Unlike vinyl covers, the cover can last as long as the vehicle., Engineers at Toyota used plastic to make a more durable spare-tire cover on the RAV4 sport-utility vehicle and simultaneously improve its looks. The rigid cover, which replaces a vinyl version, [...]

E and E Manufacturing Co.'s nut stamping operations suffered an average downtime of two-and-a-half hours per shift because its D2 and M2 tool steel punches chipped after only 2,000-3,000 cycles. The company turned to molybdenum powder-based Mico-Melt M-4 developed by Carpenter Technology Corp. By using the M-4 tool punches, E and E Manufacturing was able to increase its production by three-fold and increase the quality of its products., Engineers at E & E Manufacturing Co., an automotive-stamping plant located in Plymouth, Mich., were faced with the challenge of finding a more durable tool-punch material. Punches made from D2 [...]

A major power-tool manufacturer has been able to reduce manufacturing costs at its nail-gun assembly line by 50% after installing an injection-moldable polyimide developed by Mitsui Toatsu Chemicals Inc. Called Aurum, the polyimide allows workers to mold complex, tight-tolerance seal rings that do not need machining. Aurum not only reduces molding costs and production times, it also minimizes scrap costs because it is recyclable., Looking for ways to increase productivity and reduce costs, engineers at a major power-tool manufacturer replaced a compression-molded seal with injection-moldable polyimide from Mitsui Toatsu Chemicals Inc., Purchase, N.Y. The [...]

The 1995 Ford Thunderbird LX is a $19,520 automobile that features an optional, 4.6-liter V-8 engine that generates 205 horsepower and 265 lb-ft of torque. Speed-sensitive steering comes with the 4.6-liter engine. The automobile is equipped with six-way adjustable seats with lumbar supports and digital controls. However, the center-console armrest should be left open to use the cupholders. In addition, the power-window, mirror, and door-lock controls are awkwardly angled, which make operation difficult particularly in the dark., Sporty, yet practical, that's the '95 Thunderbird. Like many consumers who can only afford one car, I struggle between buying a cramped, fun-to-drive sports car or a roomy, less-responsive, practical [...]

SatCon Technology Corp. is developing flywheel energy storage systems that are intended to replace environmentally-damaging lead-acid batteries. The systems are lighter and safer can be used for a wide range of applications, ranging from small computer networks to a whole banking system. SatCon has used a flywheel system to develop a hybrid electric race car called the Patriot., Manufacturing plants, satellites, and automobiles all use lead-acid batteries as energy sources. Whether they backup a power supply on a production floor or maneuver a space vehicle, lead-acid batteries can [...]

Focuses on the application of plastics in shielding electronics from electromagnetic interference. Basics of shielding; Choice of the right resin; Design solutions.

Provides information on several high technology coatings which protect components from wear and other elements. Advantages of powder coatings over fluid coatings; Types of powder coatings; Summary of the fluid coatings commonly used to protect engineering materials.

Talks about precision metal stamping which forms tight-tolerance parts in high volumes and with a process that lends itself to automated assembly operations. Stamping basics; Design tips; Automating assembly.

Provides information on the development of `Design for Manufacturing and Assembly' (DFMA) and `Design for the Environment' (DFE) computer software for the use of design for manufacturing and assembly. Focus of the software package; What the software DFMA consist of; Features of the computer software packages; Analysis of the software packages.

Part I. Reports that automobile manufacturers are forced the make lighter cars with the use of plastic components, as a result of government regulations, such as corporate average fuel company (CAFE) and emissions standards. Where plastics were only found; Role of engineered resins; Type of applications used by engineers; Details on manifolds. INSET: Advanced composite materials.

Looks at the use of soft-touch elastomers by manufacturers as a cost effective means for improving the design of consumer products. Percentage of handles which will have some form of soft grip; Design concepts behind soft touch instruments; Engineering properties of elastomeric materials. INSETS: Guidelines for designing grips;Manufacturing methods for applying soft-touch grips;Engineering properties of elastomeric materials.

Provides information on designs using plastic springs. Definition of a spring; Use of springs; Identification of spring material; Key characteristic of springs. INSET: Calculating spring thickness..

Focuses on clad metals and the development of the cold-bonding method called `pressure/temperature' (P/T). Examples of clad metals; History of the development of P/T; How engineers use clad metals.

Focuses on developments in polyketone chemistry which has led to a boost in gear performance. Details on the various industrial applications of polymers; Moisture absorption and dimensional change of gear materials. INSET: Getting a solid gear-tooth design..

Reports that thermoformed boat hulls eliminate environmental concerns, associated with traditional fiberglass manufacturing while improving consistency and productivity. Other advantages compared to the traditional fiberglass-manufacturing processes; What is the first step in making a thermoformed boat hull; Ease at which a damage thermoformed hull can be repaired. INSET: Boosting stiffness with sandwich structures..

Focuses on the application of high-tech substances to sporting equipment to achieve high levels of performance. ProKennex experience with carbon-graphite in their hockey equipment; Comments from V-Formation Incorporated's seniors vice president, Michael Delia; Morrow Snowboards Incorporated's way for boosting productivity and meeting challenges of harsh weather; Champion Boats range of vessels for navigation when fishing. INSET: Fluorothermoplastics give a clearer view of Greenland..

Presents information about specialty metals being specified by engineers to make durable automobiles that approach maintenance-free operation, comply with warranties, and meet consumer expectations staying within government requirements. How stainless steels are used; How steelmakers are improving material processibility; Importance of magnetic steels.

Introduces equipment and supplies of interest to the semiconductor industry. Manufacturing of semiconductor devices from high-performance plastics; Advantages of engineering resins; Problems addressed by plastic devices; Includes electrostatic discharge and harsh environments; Plastics used in the semiconductor industry; Features and applications of the devices.

Focuses on various applications of the expanded polypropylene foam. Comparison with other foams; Automotive applications; Computer packaging; Sporting goods; Properties of low-density EPP foam beads; Strength; Elongation; Water absorption; Thermal conductivity. INSETS: Riding with EPP.;Cradling computers.;Getting under the skin..

Discusses the uses of castable epoxy resins in the machine-tool industry. Structural properties of cast epoxies; Introduction of castable polymers; Advantages of using castable epoxy; Better machines with cast polymers; Low coefficient of friction; Excellent vibration damping; Problems when designing with cast epoxies. INSET: Polymer concrete and castable epoxy..

Reports on the participation of material suppliers in the development of plastic automotive parts. Responsibility for design by resin suppliers; Minimization of development time; Importance of knowledge about resin properties. INSETS: Plastic shows its mettle in molding steering shafts.;Plastic retainers make for lighter valve springs..

Reports on the development of direct shell production casting (DSPC) technique that allows the making of molds directly from computer models, hastening the production of die-cast and injection-molded parts. Description of technology; Features of turnkey system. INSETS: One-stop shop.;Taking it a step further..

Offers advice on how to choose heat-resistant plastics. Evaluation of the operating conditions of the material; Heat deflection temperature of plastics; Relative thermal index; Maximum service temperature; Detailed design considerations. INSETS: Checklist for designers.;Software helps choose materials..

Discusses the differences between virgin and reprocessed (repro) polytetrafluoroethylene (PTFE) resin. Components and properties of virgin and repro resins; Comparison of mechanical test data taken from sheets and rod made of virgin and repro resin.